Flue gas desulfurization system

ABSTRACT

A flue gas desulfurization process and system that utilize ammonia as a reactant, and in which any hydrogen sulfide and/or mercaptans within the ammonia are separated during the desulfurization process so as to prevent their release into the atmosphere. The process and system entail absorbing acidic gases from a flue gas with a scrubbing media containing ammonium sulfate to produce a stream of scrubbed flue gas, collecting the scrubbing media containing the absorbed acidic gases, injecting into the collected scrubbing media a source of ammonia that is laden with hydrogen sulfide and/or mercaptans so that the injected ammonia is absorbed into and reacted with the collected scrubbing media, stripping the hydrogen sulfide and/or mercaptans from the collected scrubbing media by causing the hydrogen sulfide and/or mercaptans to exit the collected scrubbing media as stripped gases, and collecting the stripped gases without allowing the stripped gases to enter the stream of scrubbed flue gas.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a division patent application of co-pending U.S. patentapplication Ser. No. 12/109,441, filed Apr. 25, 2008, the contents ofwhich are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention generally relates to processes and systems forremoving acidic gases from flue gases produced by power generation,industrial, and other facilities. More particularly, this invention isdirected to flue gas desulfurization (FGD) processes and systems thatutilize ammonia to capture sulfur dioxide and produce ammonium sulfate,with the further capability of preventing or at least reducing therelease of hydrogen sulfide and/or mercaptans into a scrubbed flue gasstream produced by such processes and systems.

Acidic gases, including sulfur dioxide (SO₂), hydrogen chloride (HCl)and hydrogen fluoride (HF), are known to be hazardous to theenvironment, and as a result their emission into the atmosphere isclosely regulated by clean air statutes. For the removal of acidic gasesfrom flue gases produced by utility and industrial plants, gas-liquidscrubbers (contactors, absorbers, etc.), are widely employed. Scrubbersgenerally employ a liquid-containing media that is brought into intimatecontact with a flue gas to remove acidic gases by absorption. Theprocess by which acidic gases are removed from flue gases in this manneris generally referred to as wet flue gas desulfurization (wet FGD).

The cleansing action produced by scrubbers is generally derived from thepassage of a flue gas through a tower cocurrently or countercurrently toa descending liquid medium. Calcium-based slurries, sodium-basedsolutions and ammonia-based solutions are typical alkaline scrubbingmedia used in flue gas scrubbing operations. The cleansed gases areallowed to exit the tower, typically passing through a mist eliminatorto atmosphere. The liquid medium and its absorbed gases are collected ina tank, typically at the bottom of the tower, where the absorbed gasesare reacted to form byproducts that are useful or at least not harmfulto the environment. While scrubbers utilizing calcium-based slurriesgenerally perform satisfactorily, their operation results in theproduction of large quantities of wastes or gypsum, the latter havingonly nominal commercial value.

In contrast, ammonia-based scrubbing processes have been used to producea more valuable ammonium sulfate fertilizer, as taught by U.S. Pat. Nos.4,690,807 and 5,362,458, each of which are assigned to the assignee ofthe present invention and incorporated herein by reference. In theseprocesses (also known as ammonium sulfate flue gas desulfurization, orAS FGD), the scrubbing solution is accumulated in a tank where theabsorbed sulfur dioxide reacts with dissolved ammonia (NH₃) to formammonium sulfite ((NH₄)₂SO₃) and ammonium bisulfite (NH₄HSO₃), which areoxidized in the presence of sufficient oxygen to form ammonium sulfate((NH₄)₂SO₄) and ammonium bisulfate (NH₄HSO₄), the latter of which reactswith ammonia to form additional ammonium sulfate. A portion of theammonium sulfate solution and/or ammonium sulfate crystals that form inthe solution can then be drawn off to yield the desired byproduct ofthis reaction.

Ammonia produced from sour water in refinery, tar sands and othersimilar applications typically contains low concentrations of hydrogensulfide (H₂S) and mercaptans (or thiols, which are compounds thatcontain the functional group composed of a sulfur atom and a hydrogenatom (—SH)). When the ammonia is used in an ammonium sulfate FGD systemto capture sulfur dioxide, the hydrogen sulfide and mercaptans arestripped from the ammonia because of their volatility in ammoniumsulfate, and thereafter become entrained with the flue gas. Scrubbedflue gases that exit the FGD system contain the entrained hydrogensulfide and mercaptans which, in addition to being air pollutants, cancontribute an undesirable odor to the FGD emissions.

Current technologies employed to purify ammonia and separate it fromhydrogen sulfide and mercaptans are expensive capital-intensiveprocesses, and consume considerable amounts of energy. As such, it wouldbe desirable if an improved process were available that was capable ofgreatly reducing the amounts of hydrogen sulfide and mercaptans releasedfrom AS FGD systems, while also avoiding the disadvantages of prior artprocesses.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a flue gas desulfurization process andsystem that utilize ammonia as a reactant, and in which any hydrogensulfide and/or mercaptans within the ammonia are separated during thedesulfurization process so as to prevent their release into theatmosphere.

According to a first aspect of the invention, the process includesabsorbing acidic gases from a flue gas with a scrubbing media containingammonium sulfate to produce a stream of scrubbed flue gas, collectingthe scrubbing media containing the absorbed acidic gases, injecting intothe collected scrubbing media a source of ammonia that is laden withhydrogen sulfide and/or mercaptans so that the injected ammonia isabsorbed into and reacted with the collected scrubbing media, strippingthe hydrogen sulfide and/or mercaptans from the collected scrubbingmedia by causing the hydrogen sulfide and/or mercaptans to exit thecollected scrubbing media as stripped gases, and collecting the strippedgases without allowing the stripped gases to enter the stream ofscrubbed flue gas.

According to a second aspect of the invention, the system includes meansfor absorbing acidic gases from a flue gas with a scrubbing mediacontaining ammonium sulfate to produce a stream of scrubbed flue gas,means for collecting the scrubbing media containing the absorbed acidicgases, means for injecting into the collected scrubbing media a sourceof ammonia that is laden with hydrogen sulfide and/or mercaptans so thatthe injected ammonia is absorbed into and reacted with the collectedscrubbing media, means for stripping the hydrogen sulfide and/ormercaptans from the collected scrubbing media by causing the hydrogensulfide and/or mercaptans to exit the collected scrubbing media asstripped gases, and means for collecting the stripped gases withoutallowing the stripped gases to enter the stream of scrubbed flue gas.

In flue gas desulfurization processes and systems of this invention, thescrubbing media can be collected in a tank, and the hydrogen sulfideand/or mercaptans can be stripped from the scrubbing media in the tankor in a separate vessel fluidically connected to the tank. In eithercase, it can be seen that a significant advantage of this invention isthat ammonia containing undesired levels of hydrogen sulfide andmercaptans can be used in a desulfurization process, but with a greatlyreduced risk of releasing gaseous hydrogen sulfide and mercaptans intothe atmosphere along with the scrubbed flue gas. As such, the presentinvention is capable of avoiding disadvantages associated with currenttechnologies used to purify ammonia and separate it from hydrogensulfide and mercaptans prior to its use in an ammonium sulfate-basedflue gas desulfurization process.

Other objects and advantages of this invention will be betterappreciated from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a flue gas scrubbing apparatusconfigured for in situ removal of hydrogen sulfide and mercaptans inaccordance with a first embodiment of this invention.

FIG. 2 is a schematic representation of a flue gas scrubbing apparatusequipped with a dedicated stripping tank for removal of hydrogen sulfideand mercaptans in accordance with a second embodiment of this invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 represent two embodiments of ammonia-based FGD systems 10and 100 that allow the use of ammonia containing hydrogen sulfide and/ormercaptans. The systems 10 and 100 employ a relatively lowcost processfor reducing the release of hydrogen sulfide and mercaptans byseparating and capturing these pollutants after they are stripped fromthe contact media used in the AS FGD process. The process can beintegrated into an otherwise conventional AS FGD system and operationthrough relatively uncomplicated modifications to the AS FGD system,incurring minimal capital investment and energy consumption. FIGS. 1 and2 are drawn for purposes of clarity when viewed in combination with thefollowing description, and therefore are not necessarily to scale.

The invention utilizes the fact that ammonia is soluble in water andacidic solutions, while the solubilities of hydrogen sulfide andmercaptans in water and acidic solutions are lower. Ammonium sulfatescrubbing media (including solutions and slurries, depending on solidscontent) accumulated in AS FGD systems after the absorption of sulfurdioxide from flue gases are acidic, with pH levels typically in a rangeof about 4 to about 6. When ammonia laden with hydrogen sulfide and/ormercaptans is introduced into the ammonium sulfate media, the ammonia isreadily absorbed and reacts with the absorbed sulfur dioxide, while thehydrogen sulfide and mercaptans are stripped from the liquid to the gasphase. In typical FGD systems, the reaction tank in which the scrubbingmedia is accumulated is often open at its upper end. Air that has beeninjected into the scrubbing media to react and form ammonium sulfatemixes with the stripped hydrogen sulfide and mercaptans, and theresulting mixture is then able to mix with the scrubbed flue gases,producing an undesirable odor and emission of harmful species.

The present invention reduces the release of hydrogen sulfide andmercaptans by adding the hydrogen sulfide and mercaptans-laden ammoniato the ammonium sulfate media in such a way that stripping of hydrogensulfide and mercaptans occurs in a confined zone, thus avoiding themixing of hydrogen sulfide and mercaptans gases with the scrubbed fluegas. The gaseous hydrogen sulfide and mercaptans are then diverted awayfrom the FGD system, and can be captured, incinerated, or otherwiseprevented from release into the atmosphere.

In accordance with the above, the AS FGD systems 10 and 100 representedin FIGS. 1 and 2 are each configured to separate hydrogen sulfide andmercaptans and prevent the contamination of a flue gas. The FGD systems10 and 100 are generally represented as being of a type that scrubs fluegases produced by the burning of fossil fuels or another process thatresults in the flue gas containing acidic gases, such as sulfur dioxide,hydrogen chloride and/or hydrogen fluoride, as well as particulatematter, nitrogen oxides (NOx), etc. Referring to FIG. 1, theconventional components of the FGD system 10 include an absorber tower14 having a contact zone 16 in which an ammonium sulfate scrubbing media(e.g., solution or slurry) 26 is brought into contact with a flue gasthat enters the FGD system 10 through an inlet duct 12. The scrubbingmedia 26 is shown as being collected in a tank 18 located at the bottomof the tower 14. The media 26 is drawn from the tank 18 with a pump 20and then delivered through a pipe 22 to the contact zone 16, where thescrubbing media 26 is dispersed with spray nozzles 24 or anothersuitable delivery device. After being scrubbed by the scrubbing media26, the resulting scrubbed stream of flue gas flows upward, typicallythrough a mist eliminator and/or other equipment (not shown), and iseventually released to atmosphere through a chimney or other suitablestructure. As with many existing wet flue gas desulfurizationfacilities, the FGD system 10 is equipped for in situ forced oxidationof the scrubbing media 26 that has collected in the tank 18. In FIG. 1,a suitable source 30 of oxygen, such as air or another oxygen-containinggas (hereinafter referred to as air for convenience), is represented asbeing introduced into the tank 18 with a sparger 28 connected to theoxygen source 30. The air is typically injected near the bottom of thetank 18, so that the gas migrates upward as bubbles 48 through thescrubbing media 26 in the tank 18. In this manner, reaction productsproduced by contacting the acidic gases of the flue gas with thescrubbing media 26 are oxidized by the oxygen in the sparged air topreferably yield ammonium sulfate as a useful fertilizer byproduct.

As taught by commonly-assigned U.S. Pat. Nos. 4,690,807 and 5,362,458,following absorption of the acidic gases present in a flue gas, theammonium sulfate media 26 collected in the tank 18 has a relatively lowpH, for example, about 4 to about 6. Aqueous ammonia (ammoniumhydroxide, NH₄OH) or another source of ammonia 31 is introduced into thecollected media 26, such as with a second sparger 32, typically near thetop of the reaction tank 18 and preferably a meter or so below thesurface of the scrubbing media 26 in the tank 18. The absorbed sulfurdioxide reacts with the ammonia to form ammonium sulfite (NH₄)₂SO₃ andammonium bisulfite (NH₄HSO₃), which are then oxidized in the presence ofsufficient oxygen (introduced by the sparger 28) to form precipitates ofammonium sulfate and ammonium bisulfate (NH₄HSO₄). Ammonium bisulfateundergoes a second reaction with the injected ammonia to form additionalammonium sulfate precipitate. A portion of the ammonium sulfate media 26is typically removed from the tank 18 and dewatered with a suitabledewatering device (not shown) to precipitate ammonium sulfate, which canthen be sold as a valuable fertilizer. If hydrogen chloride and hydrogenfluoride were present in the flue gas, as is typically the case withflue gas produced by the combustion of coal, these acidic gases are alsocaptured to form ammonium chloride and ammonium fluoride, which can beremoved in the same manner. Further details regarding thedesulfurization of flue gases can be obtained in the prior art,including the above-noted U.S. Pat. Nos. 4,690,807 and 5,362,458, andtherefore will not be discussed in any further detail here.

Any hydrogen sulfide and mercaptans present in the ammonia introducedwith the sparger 32 will also be present in the scrubbing media 26collected in the tank 18. A portion of the absorbed hydrogen sulfide andmercaptans is likely to be stripped from the scrubbing media 26 by theaction of the oxidation air introduced into the scrubbing media 26 bythe sparger 28, with the result that the oxidation air released from thesurface of the scrubbing media 26 in the tank 18 (as represented by thearrows in FIG. 1) will be accompanied by gaseous hydrogen sulfide andmercaptans. To inhibit mixing of the oxidation air and gaseous hydrogensulfide and mercaptans released from the scrubbing media 26 with theflue gas traveling through the contact zone 16, FIG. 1 shows a divider34 separating the reaction tank 18 from the contact zone 16. The divider34 is represented as having an inverted conical shape, with a passage 36located at its central lowermost extent through which the scrubbingmedia 26 can enter the tank 18 following contact with the flue gas inthe contact zone 16. The passage 36 is represented as being entirelyopen at its upper limit 38 and closed at its lower limit 40, which issubmerged below the surface of the scrubbing media 26 in the tank 18.The passage 36 further has one or more submerged peripheral openings 42located at its perimeter near its closed lower limit 40, and throughwhich the scrubbing media 26 is able to flow directly into the collectedmedia 26 within the tank 18.

The inverted conical shape of the divider 34 and the size andconfiguration of the passage 36 cause the oxidation air and gaseoushydrogen sulfide and mercaptans released from the scrubbing media 26 toflow toward the perimeter of the tank 18 above the scrubbing media 26,and into a confined zone 44 bounded by the surface of the scrubbingmedia 26, the divider 34, the exterior of the passage 36, and theexposed wall of the tank 18 between the surface of the scrubbing media26 and the divider 34. From the confined zone 44, the gaseous hydrogensulfide and mercaptans can be diverted through a pipe 46 or othersuitable structure and subsequently captured, incinerated, or otherwisedisposed of or processed in any desirable manner.

The FGD system 100 represented in FIG. 2 provides an alternativeconfiguration capable of removing hydrogen sulfide and mercaptansbrought into the system 100 with ammonia. Because of the similarities intheir construction and operation, consistent reference numbers are usedto identify functionally similar structures in FIGS. 1 and 2. The system100 of FIG. 2 primarily differs from that of FIG. 1 by providing adedicated hydrogen sulfide and mercaptans stripping vessel 50 in closeproximity to the tower 14, the latter of which again includes a contactzone 16 and reaction tank 18 whose purposes are essentially the same asdescribed for the embodiment of FIG. 1. The reaction tank 18 and thestripping vessel 50 are connected near their lower ends via a passage 62that provides for equalization of the liquid levels in the tank 18 andvessel 50.

As in the system 10 of FIG. 1, the system 100 of FIG. 2 utilizes a pump20 to draw the ammonium sulfate scrubbing media 26 from the reactiontank 18, and then deliver the drawn media 26 through a pipe 22 tonozzles 24 located in the contact zone 16 of the tower 14. In addition,a portion of the scrubbing media 26 is shown as being delivered by thepump 20 through a second pipe 52 to the stripping vessel 50, where thescrubbing media 26 is injected into the scrubbing media 26 within thevessel 50 at some distance below the surface of the scrubbing media 26in the vessel 50. For the reasons described in reference to the system10 of FIG. 1, air is preferably injected with a sparger 28 into thescrubbing media 26 near the bottom of the reaction tank 18. Air is alsoinjected into the stripping vessel 50 with a sparger 58, preferably atroughly the same elevation as the air injection site in the reactiontank 18. Instead of being injected into the reaction tank 18 as done inFIG. 1, ammonia (and any hydrogen sulfide and/or mercaptans containedtherein) is drawn from a suitable source 31 and injected with a sparger32 into the stripping vessel 50. Similar to FIG. 1, the ammonia ispreferably injected near the top of the vessel 50, for example, a meteror so below the surface of the scrubbing media 26 in the vessel 50, andpreferably below the location where the scrubbing media 26 is introducedinto the vessel 50. Alternatively, the ammonia laden with hydrogensulfide and mercaptans can be injected into the pipe 52, so as to bemixed and delivered with the recycled media 26 to the vessel 50.

The injected ammonia is captured by the low-pH media 26 as it flowsdownwardly through the stripping vessel 50 toward the tank 18. In sodoing, the media 26 within the vessel 50 flows counter-currently to theair injected into the vessel 50 with the sparger 58. Simultaneously, thehydrogen sulfide and mercaptans introduced with the ammonia into thevessel 50 are stripped out of the scrubbing media 26 by the upward flowof bubbles 48 from the air sparger 58. Air and the stripped gaseoushydrogen sulfide and mercaptans exit the scrubbing media 26 and enterthe confined zone 44 between the surface of the scrubbing media 26 inthe vessel 50 and the top of the vessel 50, and from there can bediverted through a pipe 46 or other suitable structure and subsequentlycaptured, incinerated, or otherwise disposed of or processed in anydesirable manner. The pH of the scrubbing media 26 increases as it flowsdownward through the stripping vessel 50 as a result of the capturedammonia, and is returned by gravity to the reaction tank 18 through thepassage 62.

In view of the above, it can be appreciated that the systems 10 and 100effectively isolate and remove hydrogen sulfide and mercaptans that aretypically present in sources of ammonia (e.g., aqueous ammonia) used inAS FGD processes, and otherwise escape into the atmosphere with thescrubbed flue gases. As such, the invention avoids the disadvantages ofcurrent technologies that seek to avoid hydrogen sulfide and mercaptansby purifying ammonia using expensive and capital-intensive processes.

While the invention has been described in terms of specific embodiments,it is apparent that other forms could be adopted by one skilled in theart. For example, the physical configuration of the systems 10 and 100could differ from that shown, and components other than those notedcould be used, including devices other than spargers and nozzles thatare adequately capable of dispensing fluids including air, ammonia, andscrubbing media in a suitable manner. Therefore, the scope of theinvention is to be limited only by the following claims.

The invention claimed is:
 1. A flue gas desulfurization systemcomprising: means for absorbing acidic gases from a flue gas, theabsorbing means comprising a tower, a contact zone within the tower, aninlet into the tower through which the flue gas enters the tower, andmeans for contacting the flue gas within the tower with a scrubbingmedia containing ammonium sulfate to produce a stream of scrubbed fluegas; means for collecting the scrubbing media containing the absorbedacidic gases, the collecting means comprising a tank in which thescrubbing media containing the absorbed acidic gases is collected todefine a quantity of collected scrubbing media within the tank, the tankhaving an inlet below a surface of the collected scrubbing media throughwhich the scrubbing media is received and an outlet below the inlet sothat the collected scrubbing media flows downwardly from the inlet tothe outlet of the tank; means for injecting a source of ammonia into thecollected scrubbing media between the inlet and the outlet of the tank,the source of ammonia being laden with at least one compound chosen fromthe group consisting of hydrogen sulfide and mercaptans, the source ofammonia being absorbed into and reacted with the collected scrubbingmedia; means within the tank for stripping the at least one compoundfrom the collected scrubbing media by causing the at least one compoundto exit the collected scrubbing media as stripped gases, the strippingmeans comprising means for injecting an oxygen-containing gas into thecollected scrubbing media at a location below where the source ofammonia is injected into the collected scrubbing media and above theoutlet of the tank; means for collecting the stripped gases of the atleast one compound without allowing the stripped gases to enter thestream of scrubbed flue gas; and means for isolating and removing the atleast one compound from the flue gas desulfurization system.
 2. The fluegas desulfurization system according to claim 1, wherein the collectedscrubbing media within the tank flows counter-currently to theoxygen-containing gas within the tank and the at least one compound isstripped from the collected scrubbing media by bubbles of theoxygen-containing gas that are formed by the means for injecting theoxygen-containing gas and rise through the collected scrubbing media. 3.A flue gas desulfurization system comprising: means for absorbing acidicgases from a flue gas, the absorbing means comprising a tower, a contactzone within the tower, an inlet into the tower through which the fluegas enters the tower, and means for contacting the flue gas within thetower with a scrubbing media containing ammonium sulfate to produce astream of scrubbed flue gas; means for collecting the scrubbing mediacontaining the absorbed acidic gases, the collecting means comprising atank located beneath the contact zone and into which the scrubbing mediacontaining the absorbed acidic gases is collected from the contact zoneto define a quantity of collected scrubbing media within the tank, thetank having an inlet below a surface of the collected scrubbing mediathrough which the scrubbing media is received from the contact zone andan outlet below the inlet so that the collected scrubbing media flowsdownwardly from the inlet to the outlet of the tank; means for injectinga source of ammonia into the collected scrubbing media between the inletand the outlet of the tank, the source of ammonia being laden with atleast one compound chosen from the group consisting of hydrogen sulfideand mercaptans, the injected ammonia being absorbed into and reactedwith the collected scrubbing media; means within the tank for strippingthe at least one compound from the collected scrubbing media by causingthe at least one compound to exit the collected scrubbing media asstripped gases, the stripping means comprising means for injecting anoxygen-containing gas into the collected scrubbing media at a locationbelow where the source of ammonia is injected into the collectedscrubbing media and above the outlet of the tank; means for collectingthe stripped gases of the at least one compound without allowing thestripped gases to enter the stream of scrubbed flue gas; and means forisolating and removing the at least one compound from the flue gasdesulfurization system.
 4. The flue gas desulfurization system accordingto claim 3, wherein the tank and the contact zone are verticallyseparated by a divider, the scrubbing media containing the absorbedacidic gases flows through the divider and through the inlet to the tankbefore flowing directly into the collected scrubbing media alreadypresent in the tank, and the stripped gases are collected in a confinedzone between the divider and the surface of the collected scrubbingmedia within the tank.
 5. The flue gas desulfurization system accordingto claim 4, wherein the scrubbing media containing the absorbed acidicgases flows directly into the collected scrubbing media within the tankthrough a lower portion of the divider that is submerged in thecollected scrubbing media in the tank and defines the inlet to the tank.